Microscopic topographical analysis of tool vibration effects on diamond turned optical surfaces

In diamond turning for the manufacture of optical surfaces, a certain degree of relative vibration is inevitably encountered between the tool and work, deteriorating the surface quality. In this paper we first describe how the tool vibration affects the surface profiles in microscopic level, and then propose a metrological scheme to identify any existence of tool vibration with a minimum effort of surface measurement and analysis.     

Tribological analysis of fracture conditions in thin surface coatings by 3D FEM modelling and stress simulations

A tribological analysis of deformations and stresses generated and their influence on crack generation and surface fracture in a coated surface loaded by a sliding sphere in dry conditions is presented. A three-dimensional finite element method (3D FEM) model has been developed for calculating the first principal stress distribution in the scratch tester contact of a diamond spherical tip with 200 μm radius sliding with increasing load on a 2 μm thick titanium nitride coated steel surface. The model is comprehensive in that sense that it considers elastic, plastic and fracture behaviour of the surfaces. The hard coating will be stretched and accumulates high tensile stresses. At the same time, it is carrying part of the load and thus reducing the compressional stresses in the substrate under the sliding tip. The first crack is initiated at the top of the coating from bending and pulling actions and it grows down through the coating. The fracture toughness of the coating is calculated by identifying from a scratch test experiment the location of the first cracks and the crack density and using this as input data.     

Deformation analysis of micro/nano indentation and diamond grinding on optical glasses

The previous research of precision grinding optical glasses with electrolytic in process dressing (ELID) technology mainly concentrated on the action of ELID and machining parameters when grinding,whic...     

基于有限元法的半轴强度和疲劳寿命计算

传统的根据经验公式校核半轴强度的方法存在计算时间长、计算精度低等缺点,利用有限元法可方便的在半轴三维建模、有限元网格划分的基础上进行半轴强度分析,同时可在强度分析的基础上进行半轴寿命的计算.通过建立半轴的三维模型,划分网格,在有限元的理论基础上对半轴进行强度校核,同时结合有限疲劳寿命设计理论进行疲劳寿命的计算,得出汽车半轴的应力和使用疲劳寿命.     

Development of coating method of titanium carbide and titanium carbonitride on diamond

Fracture and drop-off of diamond grains are thought to be suppressed if the diamond grains used, such as those for electroplated wires, are coated with a material having a higher coefficient of thermal expansion than diamond and having good adhesion to the binder metal. In this study, we selected titanium carbide and titanium carbonitride as materials with such characteristics, and investigated their coating methods. The titanium carbide coating was formed by heating a mixture of diamond plate or diamond grains and titanium powder in vacuum at a temperature lower than the melting point of titanium. Titanium carbonitride formation tests were performed in two ways: by forming a titanium carbide coating and titanium carbonitride in the same chamber continuously or by exposing the sample to the atmosphere after titanium carbide formation and subsequently reheating it in nitrogen. The titanium carbide coating was tested by heating the mixture of the diamond plate and the titanium grains in vacuum of 2.0 × 10⁻³ Pa or less at 1073–1273 K for 60–120 min. For the titanium carbonitride coating, the primary titanium carbide coating was applied at temperatures of 1123–1273 K for 60 min. Then the titanium carbonitride formation was done at the same temperature but with different heating times. Products on the diamond after heating tests were analyzed using X-ray diffraction. Results show that titanium carbide can be coated onto the diamond surface by heating the mixture of diamond and titanium powder in vacuum at 1073 K or at a higher temperature. Results demonstrated further that titanium carbonitride can be formed by heating the diamond plate or the diamond grains coated with titanium carbide in nitrogen at a temperature higher than 1123 K. The titanium carbide layer thickness and the ratio of nitrogen in the titanium carbonitride increased concomitantly with increased heating temperature and increased heating time.     

高非线性光子晶体光纤中布拉格光栅的制作

采用相位掩模版法实验研究了高非线性掺锗光子晶体光纤中布拉格光栅的制作。实验中采用的光子晶体光纤的非线性系数约为12 W^－1km^－1,模场直径约为2.4 mm。 分析了布拉格光栅的反射率随着曝光脉冲数的变化,随着曝光脉冲数的增加其反射率逐渐达到饱和,继续增加曝光量发射率开始下降。实验验证了可以在高非线性光子晶体中写入布拉格光栅,得到光栅的反射率为44.4%,这对于研究光纤布拉格光栅的非线性效应和应用具有重要意义。讨论了影响布拉格光栅写入效率的因素。     

An empirical survey on the influence of machining parameters on tool wear in diamond turning of large single-crystal silicon optics

We conducted a series of screening experiments to survey the influence of machining parameters on tool wear during ductile regime diamond turning of large single-crystal silicon optics. The machining parameters under investigation were depth-of-cut, feed rate, surface cutting speed, tool radius, tool rake angle and side rake angle, and cutting fluid. Using an experimental design technique, we selected twenty-two screening experiments. For each experiment we measured tool wear by tracing the tool edge with an air bearing linear variable differential transformer before and after cutting and recording the amount of tool edge recession. Using statistical tools, we determined the significance of each cutting parameter within the parameter space investigated. We found that track length, chip size, tool rake angle and surface cutting speed significantly affect tool wear, while cutting fluid and side rake angle do not significantly affect tool wear within the ranges tested. The track length, or machining distance, is the single most influential characteristic that causes tool wear. For a fixed part area, a decrease in track length corresponds to an increase in feed rate. Less tool wear occurred on experiments with negative rake angle tools, larger chip sizes and higher surface velocities. The next step in this research is to perform more experiments in this region to develop a predictive model that can be used to select cutting parameters that minimize tool wear.     

基于接触摩擦的渐变刚度钢板弹簧刚度的计算

应用基于接触摩擦的有限元方法,在Ansys中使用面一面接触单元建立钢板弹簧有限元模型。对三段式渐变刚度钢板弹簧悬架进行刚度特性计算,并与由台架试验得出实际的刚度曲线进行比较,证明模型的准确性。为加快产品的开发与变更提供有效的方法。     

KDP晶体单点金刚石超精密切削加工的发展

总结了KDP晶体材料优异的光学性能及其难加工的机械物理特性,并回顾了KDP晶体单点金刚石切削(SPDT)加工的起源,特别对KDP晶体SPDT加工技术的国内外发展状况做了着重介绍,最后展望了KDP晶体SPDT加工的未来发展趋势。     

光子晶体光纤中超连续谱宽与波长关系的研究

采用分步傅里叶方法模拟了激光脉冲在光子晶体光纤中超连续谱的产生和非线性传输。计算和分析了初始光脉冲的峰值功率和非线性效应对超连续谱形状和带宽的影响,另外,还发现了初始光脉冲的不同波长对超连续谱的频谱宽度也有直接影响。     

FDTD方法在光子晶体光纤中的应用

光子晶体光纤是近年来研究的热点,提出时域有限差分法在光子晶体光纤理论分析中应用的具体方法。通过实例计算,得到了光子晶体光纤的有效折射率等传播参量。     

超细晶粒金刚石涂层刀具高速铣削石墨的切削性能研究

选用超细晶粒和粗晶粒金刚石涂层的双刃整体硬质合金平头立铣刀,在相同切削参数下进行石墨的高速铣削加工试验.试验结果表明:超细晶粒金刚石涂层刀具具有良好的表面涂层性能,在切削过程中刀刃磨损均匀缓慢,刀具的使用寿命和工件的加工表面质量都优于粗晶粒金刚石涂层刀具,适合石墨等硬脆材料的高速切削加工.     

Dynamic measurements of damage generation in single crystal silicon due to sliding contact with a spherical diamond

Single or multiple linear unidirectional scratches were made on (111) n-type single crystal silicon surfaces, at room temperature, by a dead-loaded spherical diamond indenter translated in the [110] direction at a speed of 5 cm s⁻¹. The damage was measured with a simulated four-point probe technique consisting of a voltage detector designed and fabricated on the silicon wafer. The scratches were made between four electrical pads of the detector through which the electrical resistance of the damage region can be recorded in real time by a data acquisition system. The relative change in voltage, between 3 and 10%, was correlated to the time for the diamond to move past the probes and depended on dead load on the diamond, and the silicon properties. This measurement technique is used to develop a model for subsurface crack generation and propagation. If subsurface damage is modeled as a Hertzian crack then a measure of the voltage provides an estimate of the crack size. This relationship between the measured relative change in voltage and load on a pyramid diamond can be expressed as M(%) P^4/3.     

基于正四边形晶格的微结构光子晶体光纤的特性分析

设计了基于正四边形晶格空气孔排列的光子晶体光纤,并在此基础上,通过在纤芯附近引入不同的微结构空气孔,运用全矢量有限元差分法,对不同微结构的光子晶体光纤的模式有效折射率、限制损耗、模场有效面积、非线性系数、波导色散系数等特性参数进行了仿真与分析。结果表明:引入不同的微结构,可以减小有效模场面积和增大非线性系数;引入正四边形微结构空气孔时,其限制损耗整体变化幅度较小;引入正八边形微结构空气孔时,其对应的波导色散系数在中波段变化比较平坦,且在波长为1 550nm处波导色散系数接近于零;引入正十二边形微结构空气孔时,其波导色散系数均为负值且变化幅度不大,可以应用于光纤的色散补偿。根据对引入不同微结构的光子晶体光纤的特性研究,为进一步研究光子晶体光纤提供一定的参考。     

Surface stresses in coated steel surfaces—influence of a bond layer on surface fracture

Thin hard coatings in the thickness range of only a few micrometers deposited by physical vapour deposition (PVD) on components or tools can improve the friction and wear properties by several orders of magnitude. A 2 μm thick TiN (E=300 GPa) coating on a high-speed steel substrate with a bond layer at the interface between the coating and the substrate was modelled by micro-level three-dimensional finite-element method (3D FEM) in order to optimise a coated surface with regard to coating fracture. Both compliant low modulus (E=100 GPa) and stiff high modulus (E=500 GPa) bond layers at the coating/substrate interface of 200 and 500 nm thickness were investigated. First principal stresses were simulated for scratch test geometry in the load range of 7.5-15 N. Very high stress concentrations of above 5700 MPa tensile stresses were observed in the bond layer just behind the contact zone for the stiffer bond layer. The stiff bond layer generated 5 times higher tensile stress maxima compared to the compliant bond layer. There was approximately 3.5 times larger strain in the compliant bond layer compared to the stiff bond layer. The general coating design advice based on this exercise is that when a bond layer is used e.g. for coating/substrate adhesion improvement should the bond layer be less stiff than the coating not to generate high and critical tensile stresses. The thickness of the bond layer may vary and is not critical with respect to generated stresses in the surface.     

二维光子晶体光波导透射特性的研究

用时域有限差分方法(FDTD)研究光波在光子晶体光波导中的传播规律,发现不同形状的波导能够导引不同频率的光波。光子晶体波导的带隙宽度和透射系数与该波导的结构和参数都有很大的关系,随着介质柱半径的变化,带隙呈现一定的变化规律,介质柱半径变小,该波导的带隙向高频方向移动,且带隙的宽度变宽;而介质柱半径变大时,光波的透射峰的峰值却变得比较大,损耗变小。研究结果为光子器件的设计提供了理论依据。     

A comparative study of implicit and explicit FEM for the wrinkling prediction in the hydroforming process

The recent application of tube hydroforming in the automotive industry demands finite element analysis, since it is rapidly being used as an effective tool for the evaluation and optimisation of the design of hydroforming dies and processes. In this paper, attention is paid to the comparison of an implicit and an explicit FEM widely used for the hydroforming process. The influences of time scaling and mass scaling, which have been commonly used in order to save computational time in the explicit method, are especially investigated. The comparisons focus on the predictability of wrinkling and stress with various scaling factors in the explicit method. Through verifications with experimental results, a useful guideline in determining the scaling factors is proposed.     

Implementation of an optimum algorithm for structural reliability analysis based on FEM

To analyze structural reliability by the stochastic FE (finite element) method rapidly and efficiently, a method combined with the FE method and gradient optimum algorithm based on ANSYS was presented when referring to the geometric interpretation of structural reliability index. ANSYS-based development was adopted to implement it. Results of an example demonstrate that the method requires fewer FE calculations compared with the design point method and Monte-Carlo simulation, and achieves satisfactory accuracy. __________ Translated from Transactions of Beijing Institute of Technology, 2006, 26 (4) (in Chinese)     

Ice crystal damage and radiation effects in relation to microscopy and analysis at low temperatures

There are several limitations to the low-temperature techniques which are currently being used for the preparation, examination and analysis of biological and organic samples by means of high-energy beam instrumentation. The low thermal conductivity of samples and the inadequacy of rapid cooling techniques means that, with the exception of thin-film suspensions and the surface of impact-cooled bulk specimens which may be vitrified, ice crystals of varying sizes will be present in nearly all samples which are quench cooled. Data are presented which indicate the depth to which adequate cryo-fixation may be achieved for both morphological and analytical studies. Although dynamic processes may be time resolved in the outer parts of quench-cooled samples, the decreased freezing rate below the surface makes resolution of these processes much less certain. The quality of information which may be obtained from quench-cooled samples is limited by radiation damage. Low-dose microscopy of vitrified thin-film suspensions of macromolecules continues to provide valid structural information at the molecular level. The increased doses needed for X-ray microanalysis present serious problems with the high spatial resolution analysis of thin frozen-hydrated sections although much less damage is observed in dried samples. A case is presented for using the outer fracture faces of frozen-hydrated bulk samples for low-resolution analysis of cells and tissues.